Ford F150 Pickup. Manual — part 451

Fig. 5: Separating Front Wheel Knuckle From Front Suspension Upper Arm
Courtesy of FORD MOTOR CO.

OVERHAUL

AXLE SHAFTS

Disassembly (Inboard Joint)

1. Remove the axle shaft from the vehicle. See AXLE SHAFTS under REMOVAL & INSTALLATION.

2003 Ford Pickup F150

2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)

2. Remove the boot clamps. See Fig. 6 . Separate the boot from the inboard CV joint housing. See Fig. 7 .

Remove the retaining ring. See Fig. 8 .

3. Remove the inboard CV joint housing. See Fig. 9 . Index-mark the inner race and ball cage. See Fig. 10 .

4. Remove the six balls. See Fig. 11 . Remove the snap ring. See Fig. 12 . Remove the inner race and the

ball cage.

5. Remove the inner race and the ball cage. See Fig. 13 .

6. Remove the outboard boot clamps. Remove the outboard boot. Check the grease for contamination. See

Fig. 14 . If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV
joint and interconnecting shaft assembly if worn/damaged

Reassembly

1. If you are not replacing the outer CV joint boot, go to step 4 . If you are replacing outer CV joint boot,

position the outboard boot on the shaft. Pack the outboard CV joint with 5.82 ounces (165 grams) of
grease. Use High Temp Constant Velocity Joint Grease (E43Z-19590-A), or equivalent provided in the
boot kit.

2. Spread any remaining grease from the kit evenly inside the boot. Clean the boot mounting surface. See

Fig. 15 . Seat the boot in the joint boot groove. Position the boot clamps.

3. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig. 16 .

4. Position the inboard boot clamp on the shaft. Position the inboard boot on the shaft.

5. Position the ball cage on the shaft with the tapered end facing the boot. See Fig. 17 . Position the inner

race on the shaft with the counterbored end facing the boot. Align the index marks. See Fig. 10 . Install
the snap ring. See Fig. 12 .

6. Lubricate and position the six balls. See Fig. 11 . Use High Temp Constant Velocity Joint Grease (E43Z-

19590-A), or equivalent provided in the boot kit.

7. Fill the inboard CV joint housing with 8.29 ounces (235 grams) of grease. Use High Temp Constant

Velocity Joint Grease (E43Z-19590-A), or equivalent provided in the boot kit.

8. Position the boot clamp on the inboard CV joint housing. See Fig. 18 . Position the inboard CV joint

housing on the ball and race assembly. Install the retaining ring. See Fig. 19 .

9. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove. Set the axle

shaft assembled length to specification. See Fig. 20 . See AXLE SHAFT ASSEMBLED LENGTH
table.

CAUTION: Do not damage the boot.

NOTE:

This step is for replacing the outboard CV joint boot.

NOTE:

Tighten the through-bolt until the tool is in the closed position.

CAUTION: Do not damage the boot.

2003 Ford Pickup F150

2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)

10. Insert a dull screwdriver blade under the boot to release the pressure. See Fig. 21 .

11. Using CV Boot Clamp (205-343, T95P-3514-A), install the two boot clamps. See Fig. 22 . Install the axle

shaft in the vehicle. See AXLE SHAFTS under REMOVAL & INSTALLATION.

AXLE SHAFT ASSEMBLED LENGTH

Fig. 6: Locating CV Boot Clamps
Courtesy of FORD MOTOR CO.

NOTE:

Tighten the through-bolt until the tool is in the closed position.

Application

In. (mm)

Left & Right Side

16.43 (417.3)

2003 Ford Pickup F150

2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)

Fig. 7: Removing/Installing Inner CV Joint Boot
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

2000-03 DRIVE AXLES Axle Shafts - Front - F150 Pickup (4WD)